In August my son and I drove to Cali and picked up this gem from Jeremy Pound. It's been a long time since I've been so excited on a build. I'm calling it a patina build. I don't plan to paint or straighten anything unless I am repairing rust. I've never built a car this way. Everything else I have done in the past has been a 100 % nut and bolt restoration. It is going to take some serious self control. The plan is 109 five door soft top on a 110 frame with a L33 all aluminum 5.3 engine with a T400 mated to a lt230.

Galvanizing things maintains a patina look and allows you to modify them and protect them. I would dip the bulkhead, frame, and t-pieces lest they rust away eventually. After a year or so it gets a nice dull grey.

Galvanizing uses a LOT of heat, not sure if the Series bulkhead will react to it any differently to a Defender bulkhead but I dealt with one and it was warped very badly. We made it work but it was dozens of hours of pulling on it with ratchet straps. You might be able to if you build a jig around it with some thicker steel to prevent warpage but that's some work.

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Geared Restorations - Matt

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Galvanizing uses a LOT of heat, not sure if the Series bulkhead will react to it any differently to a Defender bulkhead but I dealt with one and it was warped very badly. We made it work but it was dozens of hours of pulling on it with ratchet straps. You might be able to if you build a jig around it with some thicker steel to prevent warpage but that's some work.

Did you have it quenched after dipping?
Avoiding rapid changes in temperature reduces warping.
Two tricks to this I've heard is specify to have it air dried instead of quenched post dipping,
And hold the bulkhead above the zinc to let it come up to temp before sending it in the dip.

Please don't galvanize the bulkhead. You will never be able to get the doors to close right. I would look into zinc.

Not wanting to start a squabble but this isn't really accurate. Many people, myself included have dipped many bulkheads without issue. Even without a "frame" (I use one but its mostly so the galvanizer can handle it easily as this is where most damage takes place).

Also, galvanizing is zinc. Hot dipped or plated. If you are talking about electroplating it's really a waste of effort, as the rust generally starts on the inside.

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Matt Browne

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I have not tried to fit anything to my bulkhead I had dipped, but don't see any warpage to speak of (I did put a bar between the mounting holes so I know the bottom width was maintained. A full frame might have ben better to avoid damage as they move it around.